JP3576767B2 - Battery pack and PTC element built in this battery pack - Google Patents

Battery pack and PTC element built in this battery pack Download PDF

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Publication number
JP3576767B2
JP3576767B2 JP25378197A JP25378197A JP3576767B2 JP 3576767 B2 JP3576767 B2 JP 3576767B2 JP 25378197 A JP25378197 A JP 25378197A JP 25378197 A JP25378197 A JP 25378197A JP 3576767 B2 JP3576767 B2 JP 3576767B2
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Prior art keywords
electrode
ptc
ptc layer
battery pack
unit cell
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JP25378197A
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Japanese (ja)
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JP2002015715A (en
Inventor
貴司 蓮沼
厚司 渡部
一夫 大崎
章善 ▲吉▼成
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Sanyo Electric Co Ltd
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Sanyo Electric Co Ltd
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Priority to JP25378197A priority Critical patent/JP3576767B2/en
Application filed by Sanyo Electric Co Ltd filed Critical Sanyo Electric Co Ltd
Priority to DE69803596T priority patent/DE69803596T2/en
Priority to CNB988108127A priority patent/CN1161847C/en
Priority to AT98943017T priority patent/ATE212477T1/en
Priority to EP98943017A priority patent/EP1026758B1/en
Priority to AU90948/98A priority patent/AU9094898A/en
Priority to US09/508,940 priority patent/US6356051B1/en
Priority to PCT/JP1998/004177 priority patent/WO1999014814A1/en
Publication of JP2002015715A publication Critical patent/JP2002015715A/en
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Publication of JP3576767B2 publication Critical patent/JP3576767B2/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/572—Means for preventing undesired use or discharge
    • H01M50/574—Devices or arrangements for the interruption of current
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2200/00—Safety devices for primary or secondary batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2200/00—Safety devices for primary or secondary batteries
    • H01M2200/10—Temperature sensitive devices
    • H01M2200/106—PTC
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/42—Grouping of primary cells into batteries

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Battery Mounting, Suspending (AREA)
  • Thermistors And Varistors (AREA)

Abstract

A battery pack and a PTC device are provided that can be used safely under large current loads by increasing the area of the incorporated PTC layer so as to decrease its internal resistance. The battery pack has a plurality of unit cells (1) placed side by side in parallel and the PTC device P to protect the unit cells (1) from overcurrents. The PTC device P has a first electrode (3) and a second electrode (4) connected to the both surfaces of the PTC layer (2). The PTC layer is formed to an outer shape that covers almost the entire of the end surfaces of the two unit cells (1) to which the first electrode (4) and the second electrode (4) are connected, and has through holes (2B) positioned against the end electrodes (1A) of the unit cells (1). The first electrode (3) and the second electrode (4) connected to the both surfaces of the PTC layer (2) are formed to an outer shape almost the same as the outer shape of the PTC layer (2); and the first electrode (3) and the second electrode (4) are connected to the end electrodes (1A) of the unit cells (1) at points where the through holes (2B) of the PTC layer (2) are located. <IMAGE>

Description

【０００１】
【発明の属する技術分野】
本発明は、ＰＴＣ素子を内蔵するパック電池の改良に関し、とくに、複数本の素電池を横に平行に並べて配設して、素電池と直列にＰＴＣ素子を接続しているパック電池とこのパック電池に内蔵されるＰＴＣ素子に関する。
【０００２】
【従来の技術】
ＰＴＣ素子は、保護素子としてパック電池に内蔵される。素電池と直列に接続されたＰＴＣ素子は、素電池に過大な電流が流れ、あるいは、電池の温度が上昇したときに電気抵抗が急激に増大して、電池電流を遮断、ないしは、ほとんど０にして電池を保護する。
【０００３】
ＰＴＣ素子を素電池と直列に接続しているパック電池は、たとえば、特開平９−６３５５３号公報に記載される。この公報に記載されるパック電池は、図１に示すように、直線上に配設されている２本の素電池１の間にＰＴＣ素子Ｐを接続している。ＰＴＣ素子Ｐは、上面を一方の素電池１の端部電極１Ａに、下面を他方の素電池１の端部電極１Ａに接続している。この構造は、素電池を直線上に配設するパック電池にＰＴＣ素子を内蔵させるのに適している。ただ、素電池を横に平行に配設するパック電池には、ＰＴＣ素子を好ましい状態で接続できない。
【０００４】
素電池を平行に配設して、ＰＴＣ素子を内蔵するパック電池は、実開平２−６９４４０号公報と、実開平６−３８１５７号公報に記載される。前者の公報に記載されるパック電池の分解斜視図を図２に示す。後者の公報に記載されるパック電池に内蔵されるＰＴＣ素子と、ＰＴＣ素子を内蔵するパック電池を図３と図４に示す。
【０００５】
図２に示すパック電池は、方形状のＰＴＣ層２の下面と上面に、第一電極３と第二電極４を接続しているＰＴＣ素子Ｐを内蔵している。第一電極３と第二電極４は、ＰＴＣ層２の両側に突出して、素電池１の端部電極１Ａに接続される。この構造のパック電池は、平行に配設される素電池１の隣接する端部電極１Ａの中間にＰＴＣ層２を配設している。
【０００６】
図３に示すＰＴＣ素子Ｐは、ＰＴＣ層２が素電池の太さにほぼ等しい外形の円盤状で、素電池の凸部電極を挿入できる形状としている。この形状のＰＴＣ層２は、凸部電極の周囲に配設できる。ＰＴＣ層２の下面には、皿状の第一電極３を接続している。第一電極３は、凸部電極を挿入するために、中央を凸に成形して、ＰＴＣ層２の中心孔２Ａに挿入している。ＰＴＣ層２の上面には、ＰＴＣ層２に沿う半球状部分に、リードを突出させる第二電極４を接続している。第一電極３は凸部電極に接続され、第二電極４は、図４に示すように、隣接して配設される素電池１の端部電極１Ａに接続される。
【０００７】
【発明が解決しようとする課題】
図２と図３に示すＰＴＣ素子Ｐは、複数本の素電池１を平行に配設するパック電池に内蔵するのに好都合である。とくに、図３に示すＰＴＣ素子Ｐは、素電池の凸部電極の周囲に配設できるので、素電池からほとんど突出しないで配設できる特長がある。
【０００８】
ただ、これ等の公報に記載されるパック電池は、ＰＴＣ層の面積に制約を受けて大きくするのが難しい。図２に示すＰＴＣ素子Ｐは、ＰＴＣ層２を大きくすると、第一電極３と第二電極４を素電池１の端部電極１Ａに接続できなくなる。このＰＴＣ素子Ｐは、隣接して配設される素電池１の端部電極１Ａの間隔よりも広くできない。
【０００９】
さらに、図３と図４に示すＰＴＣ素子Ｐは、ＰＴＣ層２の外形を、素電池１の太さよりも大きくでなきい。大きくすると、素電池１からはみ出して、パック電池を局部的に大きくするからである。さらに、この形状のＰＴＣ層２は、中心孔２Ｂも開口しているので、実質的に使用できる面積が小さくなる欠点がある。
【００１０】
ＰＴＣ素子は、素電池と直列に接続して使用されるので、通常の状態では、内部抵抗を小さくすることが大切である。ＰＴＣ素子は、ＰＴＣ層の内部抵抗と、負荷電流の自乗の積に比例した電力を消費するからである。さらに、大電流の用途に使用されるパック電池は、ＰＴＣ素子の電流も大きくなる。ＰＴＣ素子は、ＰＴＣ層の面積を大きくして、大電流に耐えるように設計できる。内部抵抗を小さくして、大電流を大きくするためには、ＰＴＣ素子のＰＴＣ層を大きな面積とすることが大切であるが、従来のパック電池は、このことを実現することが難しい欠点があった。
【００１１】
本発明は、この欠点を解決することを目的に開発されたもので、本発明の重要な目的は、ＰＴＣ層の面積を大きくして、ＰＴＣ層の内部抵抗を小さくし、大きな電流負荷に安心して使用できるパック電池とこのパック電池に内蔵されるＰＴＣ素子を提供することにある。
【００１２】
【課題を解決するための手段】
本発明の請求項１のパック電池は、横に並べて平行に配設されている複数本の素電池１と、素電池１を過大な電流から保護するＰＴＣ素子Ｐを備える。ＰＴＣ素子Ｐは、ＰＴＣ層２の両面に、第一電極３と第二電極４を接続している。ＰＴＣ素子Ｐは、端部電極１Ａを同一平面に配設しているふたつの素電池１の端部電極１Ａに、第一電極３と第二電極４を接続して、素電池１と直列に接続される。
【００１３】
ＰＴＣ層２の外形は、第一電極３と第二電極４を接続しているふたつの素電池１の端面のほぼ全体を含む形状に成形されている。さらに、ＰＴＣ層２は、素電池１の端部電極１Ａに位置して、貫通孔２Ｂを開口している。
【００１４】
ＰＴＣ層２の両面に接続される第一電極３と第二電極４は、ＰＴＣ層２の外形にほぼ等しい外形に形成され、第一電極３と第二電極４は、ＰＴＣ層２の貫通孔２Ｂに位置する部分を素電池１の端部電極１Ａに接続している。
【００１５】
本発明の請求項５のＰＴＣ素子は、ＰＴＣ層２の両面に接続している第一電極３と第二電極４を、横に並べて平行に配設される複数本の素電池１の端部電極１Ａに接続して、素電池１を過大電流から保護する。
【００１６】
ＰＴＣ層２の外形は、第一電極３と第二電極４を接続するふたつの素電池１の端面のほぼ全体を含む形状に成形されている。さらに、ＰＴＣ層は、素電池１の端部電極１Ａに位置して、貫通孔２Ｂを開口している。
【００１７】
ＰＴＣ層２の両面に接続される第一電極３と第二電極４は、ＰＴＣ層２の外形にほぼ等しい外形に形成され、第一電極３と第二電極４は、ＰＴＣ層２の貫通孔２Ｂに位置する部分を素電池１の端部電極１Ａに接続している。
【００１８】
本発明の請求項２のパック電池と、請求項６のＰＴＣ素子は、ＰＴＣ層２の上面に接続している第二電極４に、ＰＴＣ層２の貫通孔２Ｂに挿入する凸部４Ａを設けている。第二電極４は、凸部４Ａを素電池１の端部電極１Ａに接続している。なお、本明細書において、上下方向は図面に基づいて決定するものとする。
【００１９】
本発明の請求項３のパック電池と、請求項７のＰＴＣ素子は、ＰＴＣ層２の下面に接続している第一電極３を、ＰＴＣ層２の貫通孔２Ｂに位置する部分を下面から突出させて、凸部３Ａを設け、この凸部３Ａを、素電池１の端部電極１Ａに接続している。
【００２０】
本発明の請求項４のパック電池は、内蔵する素電池１を円筒電池とし、ＰＴＣ層２と第一電極３と第二電極４の外形を、長方形のコーナー部を、円筒電池に沿って面取りした形状としている。
【００２１】
【発明の実施の形態】
以下、本発明の実施例を図面に基づいて説明する。ただし、以下に示す実施例は、本発明の技術思想を具体化するためのパック電池とこのパック電池に内蔵されるＰＴＣ素子を例示するものであって、本発明はパック電池とＰＴＣ素子を下記のものに特定しない。
【００２２】
さらに、この明細書は、特許請求の範囲を理解しやすいように、実施例に示される部材に対応する番号を、「特許請求の範囲の欄」、および「課題を解決するための手段の欄」に示される部材に付記している。ただ、特許請求の範囲に示される部材を、実施例の部材に特定するものでは決してない。
【００２３】
図５と図６に示すパック電池は、ケーシング５に、２本の素電池１と、この素電池１を過電流から保護するＰＴＣ素子Ｐを内蔵している。素電池１は、ニッケル−カドミウム電池、ニッケル−水素電池、リチウムイオン二次電池等の充電できる電池である。ニッケル−カドミウム電池またはニッケル−水素電池を内蔵するパック電池は、大電流で充電して放電できる特長がある。パック電池に内蔵されるＰＴＣ素子Ｐは、素電池１に過大な電流が流れ、あるいは、素電池１の温度が上昇すると急激に電気抵抗が増大して、素電池１に流れる電流を遮断、ないしは極減する特性を有する。
【００２４】
ケーシング５は、プラスチックの成形品、あるいは、熱収縮チューブで、素電池１とＰＴＣ素子Ｐをカバーしている。図のケーシング５は、素電池１の端部電極１Ａを外部に表出させる電極窓５Ａを開口している。ただ、本発明のパック電池は、端部電極をケーシングの電極窓から外部に表出させるのではなく、端部電極に接続したリード線を、ケーシングに固定している外部電極に接続する構造とすることもできる。
【００２５】
２本の素電池１は、横に並べて平行に配設されている。図のパック電池は、２本の素電池１を平行に並べているが、本発明のパック電池は、３本以上の素電池を内蔵させることもできる。２本の素電池１は、端部電極１Ａを同一ないしほぼ平面に配設して並べている。
【００２６】
ＰＴＣ素子Ｐは、図７の分解斜視図に示すように、ＰＴＣ層２の下面に第一電極３を、上面に第二電極４を配設している。第一電極３と第二電極４は、ＰＴＣ層２の上下面に、電気的に接続される状態で接着されている。第一電極３とＰＴＣ層２と第二電極４は、図８の断面図に示すように、３層の積層状態で密着される。
【００２７】
ＰＴＣ層２は、図６の平面図と図７の分解斜視図に示すように、その外形を、長方形のコーナー部を、円筒電池に沿って面取りした形状として、隣接する２本の素電池１の端面のほぼ全体を含む形状に成形している。図のＰＴＣ層２は、その外形を、素電池１である円筒電池の外形よりもわずかに小さくしている。ＰＴＣ層は、図示しないが、その外形を、円筒電池の外形よりも多少大きくすることもできる。ただ、ＰＴＣ層が素電池から大きく突出すると、ケーシングに収納するのに都合が悪くなる。このため、ＰＴＣ層は素電池の外形からほとんど突出しない大きさとする。
【００２８】
図のパック電池は、円筒電池を内蔵している。パック電池は円筒電池でなくて、角型電池を内蔵するものもある。角型電池を内蔵するパック電池は、図９に示すように、ＰＴＣ素子Ｐを角型電池の外形に沿う長方形状として、素電池１の端面を含む形状とする。
【００２９】
ＰＴＣ層２は、素電池１の端部電極１Ａに位置して貫通孔２Ｂを開口している。貫通孔２Ｂは、第一電極３と第二電極４を、素電池１の端部電極１Ａに接続するために設けられるので、第一電極３と第二電極４を端部電極１Ａに電気接続できる大きさに開口される。図のＰＴＣ層２は、貫通孔２Ｂの大きさを、素電池１の凸部電極１ｂと同じ外形としている。ただ、貫通孔は、必ずしも、凸部電極と同じ大きさとする必要はない。凸部電極よりも大きく、あるいは小さくすることもできる。貫通孔を小さくすると、ＰＴＣ層の面積を大きくできる。ただ、小さい貫通孔は、第一電極と第二電極を端部電極に広い面積で接続するのが難しくなる。反対に、貫通孔を大きくすると、ＰＴＣ層の面積は小さくなるが、第一電極と第二電極を広い面積で端部電極に接続できる。
【００３０】
第一電極３と第二電極４は、スポット溶接して、素電池１の端部電極１Ａに接続される。したがって、貫通孔２Ｂは、ここに溶接電極を挿入して第一電極３と第二電極４を端部電極１Ａに接続できる大きさに開口される。さらに、ＰＴＣ層２の両面に接続される第一電極３と第二電極４は、溶接電極を挿入できるように、ＰＴＣ層２の貫通孔２Ｂに対向する位置に、それぞれ貫通孔３Ｂ、４Ｂを設けている。これ等の貫通孔３Ｂ、４Ｂは、ＰＴＣ層２の貫通孔２Ｂとほぼ等しい大きさに開口されている。
【００３１】
図７の第一電極３と第二電極４は薄い金属板で、ＰＴＣ層２と同じ外形に裁断している。第一電極３は、ＰＴＣ層２の貫通孔２Ｂに位置する部分を下面から突出させて凸部３Ａとし、この凸部３Ａを素電池１の端部電極１Ａに接続している。凸部３Ａは、貫通孔２Ｂよりも多少小さい外形に成形されている。
【００３２】
第二電極４は、ＰＴＣ層２の貫通孔２Ｂに挿入される凸部４Ａを成形している。この凸部４Ａは、ＰＴＣ層２を貫通して下面から突出させるために、第一電極３の凸部よりも高く突出させている。第一電極３と第二電極４は、図５に示すように、凸部３Ａ、４Ａの底面を、正確に同一平面としている。この構造の第一電極３と第二電極４は、２本の素電池１の端部電極１Ａである平面電極１ａと、凸部電極１ｂを正確に同一平面として、これ等に接続できる。
【００３３】
ただ、本発明のパック電池は、第一電極と第二電極の凸部を、必ずしも正確に同一平面に配設する必要はない。たとえば、第一電極を平面状とし、あるいは、図８において上方に突出させてＰＴＣ層の貫通孔に挿入する形状とすることもできる。ＰＴＣ層の貫通孔に挿入する凸部は、素電池の凸部電極を挿入できる大きさとして、ここに凸部電極を入れた状態で接続する。
【００３４】
以上の図に示すように、ＰＴＣ層２と同じ外形とする第一電極３と第二電極４は、ＰＴＣ層２との接触面積を大きくできる特長がある。第一電極３と第二電極４は、必ずしもＰＴＣ層２の外形に等しくする必要はない。たとえば、図示しないが、第一電極と第二電極の外形をＰＴＣ層よりも多少小さく、あるいは大きくすることもできる。
【００３５】
以上の構造のパック電池は、下記のようにして組み立てられる。
▲１▼ ＰＴＣ素子Ｐは、あらかじめ、ＰＴＣ層２の下面に第一電極３を、上面に第二電極４を接続して連結している。
▲２▼ 平行に並べた素電池１の上に、第一電極３と第二電極４を連結しているＰＴＣ素子Ｐを載せる。ＰＴＣ素子Ｐは、その外周を２本の素電池１の外周に合わせて上に載せる。
▲３▼ ＰＴＣ層２の貫通孔２Ｂに溶接電極を挿入して、第一電極３と第二電極４の凸部３Ａ、４Ａを、素電池１の端部電極１Ａにスポット溶接して連結する。
▲４▼ ＰＴＣ層２を接続した素電池１を、ケーシング５でカバーしてパック電池とする。
【００３６】
【発明の効果】
本発明のパック電池とこのパック電池に内蔵されるＰＴＣ素子は、ＰＴＣ素子の第一電極と第二電極を、素電池の端部電極に接続しやすい構造とし、さらに、ＰＴＣ素子が素電池から外部に大きく突出することなく、両面に電極を接続しているＰＴＣ層の面積を大きくできる特長がある。それは、本発明のパック電池とＰＴＣ素子が、ＰＴＣ層と第一電極と第二電極を独特の構造としているからである。ＰＴＣ層は、第一電極と第二電極を接続するふたつの素電池の端面のほぼ全体を含む形状に成形され、かつ、素電池の端部電極に位置して、貫通孔を開口している。第一電極と第二電極は、ＰＴＣ層に設けられた貫通孔の部分で素電池の端部電極に接続される。この構造で、第一電極と第二電極を端部電極に接続して、ＰＴＣ層を複数の電池の端面に配設するパック電池は、ＰＴＣ層を極めて大きな面積にして、内部抵抗を著しく小さくできる。このため、素電池を正常な状態で使用するとき、ＰＴＣ層の電流損失を極めて小さくして、素電池の電力を有効に負荷に供給できる。また、ＰＴＣ層の面積を大きくできるので、ＰＴＣ層に大電流を流すことができる。このため、本発明のパック電池とこのパック電池に内蔵されるＰＴＣ素子は、大電流の負荷に安心して、安全に使用できる特長も実現される。
【図面の簡単な説明】
【図１】従来のパック電池の断面図
【図２】従来の他のパック電池の分解斜視図
【図３】さらに従来の他のパック電池に内蔵されるＰＴＣ素子の斜視図
【図４】図３のＰＴＣ素子を内蔵するパック電池の平面図
【図５】本発明の実施例のパック電池の断面図
【図６】図５に示すパック電池の平面図
【図７】図５に示すパック電池に内蔵されるＰＴＣ素子の分解斜視図
【図８】図５に示すパック電池に内蔵されるＰＴＣ素子の断面図
【図９】本発明の他の実施例のパック電池の分解斜視図
【符号の説明】
１…素電池 １Ａ…端部電極
１ａ…平面電極 １ｂ…凸部電極
２…ＰＴＣ層 ２Ａ…中心孔 ２Ｂ…貫通孔
３…第一電極 ３Ａ…凸部 ３Ｂ…貫通孔
４…第二電極 ４Ａ…凸部 ４Ｂ…貫通孔
５…ケーシング ５Ａ…電極窓
Ｐ…ＰＴＣ素子[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a battery pack having a built-in PTC element, and more particularly to a battery pack having a plurality of unit cells arranged side by side in parallel and connecting the PTC element in series with the unit cell, and a battery pack having the same. The present invention relates to a PTC element built in a battery.
[0002]
[Prior art]
The PTC element is built in the battery pack as a protection element. A PTC element connected in series with a unit cell cuts off the battery current or reduces it to almost zero when an excessive current flows through the unit cell or the electric resistance increases rapidly when the temperature of the cell rises. To protect the battery.
[0003]
A battery pack in which a PTC element is connected in series with a unit cell is described, for example, in JP-A-9-63553. In the battery pack described in this publication, as shown in FIG. 1, a PTC element P is connected between two unit cells 1 arranged on a straight line. The PTC element P has an upper surface connected to an end electrode 1A of one unit cell 1 and a lower surface connected to an end electrode 1A of the other unit cell 1. This structure is suitable for incorporating a PTC element in a battery pack in which unit cells are arranged in a straight line. However, a PTC element cannot be connected in a favorable state to a battery pack in which unit cells are arranged horizontally and in parallel.
[0004]
A battery pack in which unit cells are arranged in parallel and which incorporates a PTC element is described in Japanese Utility Model Laid-Open No. 2-69440 and Japanese Utility Model Laid-Open No. 6-38157. FIG. 2 shows an exploded perspective view of the battery pack described in the former publication. FIGS. 3 and 4 show a PTC element incorporated in a battery pack described in the latter publication and a battery pack incorporating a PTC element.
[0005]
The battery pack shown in FIG. 2 has a built-in PTC element P connecting the first electrode 3 and the second electrode 4 on the lower surface and the upper surface of the rectangular PTC layer 2. The first electrode 3 and the second electrode 4 protrude from both sides of the PTC layer 2 and are connected to the end electrode 1A of the unit cell 1. In the battery pack having this structure, the PTC layer 2 is disposed between the adjacent end electrodes 1A of the unit cells 1 disposed in parallel.
[0006]
In the PTC element P shown in FIG. 3, the PTC layer 2 has a disk shape having an outer shape substantially equal to the thickness of the unit cell, and has a shape in which a protruding electrode of the unit cell can be inserted. The PTC layer 2 having this shape can be provided around the convex electrode. A dish-shaped first electrode 3 is connected to the lower surface of the PTC layer 2. The first electrode 3 is formed to have a convex central portion and inserted into the center hole 2A of the PTC layer 2 in order to insert the convex electrode. On the upper surface of the PTC layer 2, a second electrode 4 for projecting a lead is connected to a hemispherical portion along the PTC layer 2. The first electrode 3 is connected to the protruding electrode, and the second electrode 4 is connected to the end electrode 1A of the unit cell 1 arranged adjacently, as shown in FIG.
[0007]
[Problems to be solved by the invention]
The PTC element P shown in FIGS. 2 and 3 is convenient for incorporating a plurality of unit cells 1 in a pack battery arranged in parallel. In particular, since the PTC element P shown in FIG. 3 can be arranged around the protruding electrode of the unit cell, it has a feature that it can be arranged without protruding from the unit cell.
[0008]
However, the battery packs described in these publications are difficult to increase in size due to the limitation of the area of the PTC layer. In the PTC element P shown in FIG. 2, when the PTC layer 2 is enlarged, the first electrode 3 and the second electrode 4 cannot be connected to the end electrode 1A of the unit cell 1. The PTC element P cannot be wider than the interval between the end electrodes 1A of the unit cells 1 arranged adjacent to each other.
[0009]
Further, in the PTC element P shown in FIGS. 3 and 4, the outer shape of the PTC layer 2 must not be larger than the thickness of the unit cell 1. This is because, when the size is increased, the battery protrudes from the unit cell 1 and locally increases the size of the battery pack. Further, since the PTC layer 2 having this shape also has the center hole 2B opened, there is a disadvantage that the usable area is substantially reduced.
[0010]
Since the PTC element is used by being connected in series with a unit cell, it is important to reduce the internal resistance in a normal state. This is because the PTC element consumes power proportional to the product of the internal resistance of the PTC layer and the square of the load current. Further, in a battery pack used for a large current application, the current of the PTC element also becomes large. The PTC element can be designed so that the area of the PTC layer is increased to withstand a large current. In order to reduce the internal resistance and increase the large current, it is important that the PTC layer of the PTC element has a large area. However, the conventional battery pack has a disadvantage that it is difficult to realize this. Was.
[0011]
The present invention has been developed with a view to solving this drawback. An important object of the present invention is to increase the area of the PTC layer, reduce the internal resistance of the PTC layer, and reduce the current load. An object of the present invention is to provide a battery pack that can be used with care and a PTC element built in the battery pack.
[0012]
[Means for Solving the Problems]
The battery pack according to the first aspect of the present invention includes a plurality of unit cells 1 arranged side by side and in parallel, and a PTC element P for protecting the unit cells 1 from excessive current. The PTC element P has a first electrode 3 and a second electrode 4 connected to both surfaces of the PTC layer 2. The PTC element P connects the first electrode 3 and the second electrode 4 to the end electrodes 1A of two unit cells 1 in which the end electrodes 1A are arranged on the same plane, and is connected in series with the unit cells 1. Connected.
[0013]
The outer shape of the PTC layer 2 is formed into a shape including substantially the entire end faces of the two unit cells 1 connecting the first electrode 3 and the second electrode 4. Further, the PTC layer 2 is located at the end electrode 1A of the unit cell 1 and has a through hole 2B.
[0014]
The first electrode 3 and the second electrode 4 connected to both surfaces of the PTC layer 2 are formed to have an outer shape substantially equal to the outer shape of the PTC layer 2, and the first electrode 3 and the second electrode 4 The portion located at 2B is connected to the end electrode 1A of the unit cell 1.
[0015]
In the PTC element according to claim 5 of the present invention, the end portions of a plurality of unit cells 1 in which the first electrode 3 and the second electrode 4 connected to both surfaces of the PTC layer 2 are arranged side by side and in parallel. By connecting to the electrode 1A, the unit cell 1 is protected from an excessive current.
[0016]
The outer shape of the PTC layer 2 is formed into a shape including substantially the entire end faces of the two unit cells 1 connecting the first electrode 3 and the second electrode 4. Further, the PTC layer is located at the end electrode 1A of the unit cell 1 and has a through hole 2B.
[0017]
The first electrode 3 and the second electrode 4 connected to both surfaces of the PTC layer 2 are formed to have an outer shape substantially equal to the outer shape of the PTC layer 2, and the first electrode 3 and the second electrode 4 The portion located at 2B is connected to the end electrode 1A of the unit cell 1.
[0018]
In the battery pack according to the second aspect of the present invention and the PTC element according to the sixth aspect, the second electrode 4 connected to the upper surface of the PTC layer 2 is provided with a projection 4A inserted into the through hole 2B of the PTC layer 2. ing. The second electrode 4 connects the protrusion 4A to the end electrode 1A of the unit cell 1. In this specification, the vertical direction is determined based on the drawings.
[0019]
In the battery pack according to the third aspect of the present invention and the PTC element according to the seventh aspect, the first electrode 3 connected to the lower surface of the PTC layer 2 projects from the lower surface at a portion located in the through hole 2B of the PTC layer 2. Thus, a protrusion 3A is provided, and the protrusion 3A is connected to the end electrode 1A of the unit cell 1.
[0020]
In the battery pack according to a fourth aspect of the present invention, the built-in unit cell 1 is a cylindrical battery, and the outer shape of the PTC layer 2, the first electrode 3, and the second electrode 4 is chamfered along a rectangular corner along the cylindrical battery. Shape.
[0021]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the following examples illustrate a battery pack for embodying the technical idea of the present invention and a PTC element incorporated in the battery pack. Not specific to
[0022]
Further, in this specification, in order to make it easy to understand the claims, the numbers corresponding to the members shown in the embodiments are referred to as “claims” and “means for solving the problems”. Are added to the members indicated by "." However, the members described in the claims are not limited to the members of the embodiments.
[0023]
The battery pack shown in FIGS. 5 and 6 includes two unit cells 1 and a PTC element P for protecting the unit cells 1 from overcurrent in a casing 5. The unit cell 1 is a rechargeable battery such as a nickel-cadmium battery, a nickel-hydrogen battery, and a lithium ion secondary battery. A battery pack containing a nickel-cadmium battery or a nickel-hydrogen battery has the feature that it can be charged and discharged with a large current. In the PTC element P built in the battery pack, an excessive current flows through the unit cell 1 or the electric resistance increases rapidly when the temperature of the unit cell 1 rises, thereby interrupting the current flowing through the unit cell 1 or It has the characteristic of being extremely reduced.
[0024]
The casing 5 is a plastic molded product or a heat-shrinkable tube, and covers the unit cell 1 and the PTC element P. The illustrated casing 5 has an electrode window 5A for exposing the end electrode 1A of the unit cell 1 to the outside. However, the battery pack of the present invention has a structure in which a lead wire connected to an end electrode is connected to an external electrode fixed to the casing, instead of exposing the end electrode to the outside through an electrode window of the casing. You can also.
[0025]
The two unit cells 1 are arranged side by side and in parallel. Although the illustrated battery pack has two unit cells 1 arranged in parallel, the battery pack of the present invention may incorporate three or more unit cells. In the two unit cells 1, the end electrodes 1A are arranged on the same or substantially flat surface.
[0026]
As shown in the exploded perspective view of FIG. 7, the PTC element P has a first electrode 3 on the lower surface of the PTC layer 2 and a second electrode 4 on the upper surface. The first electrode 3 and the second electrode 4 are bonded to the upper and lower surfaces of the PTC layer 2 in a state of being electrically connected. The first electrode 3, the PTC layer 2, and the second electrode 4 are closely adhered in a three-layer state as shown in the cross-sectional view of FIG.
[0027]
As shown in a plan view of FIG. 6 and an exploded perspective view of FIG. 7, the PTC layer 2 has an outer shape in which a rectangular corner portion is chamfered along a cylindrical battery, and two adjacent unit cells 1 are formed. Is formed into a shape including substantially the entirety of the end face. The outer shape of the illustrated PTC layer 2 is slightly smaller than the outer shape of the cylindrical battery that is the unit cell 1. Although not shown, the outer shape of the PTC layer may be slightly larger than the outer shape of the cylindrical battery. However, if the PTC layer protrudes greatly from the unit cell, it becomes inconvenient to store it in the casing. For this reason, the PTC layer has a size that hardly protrudes from the outer shape of the unit cell.
[0028]
The illustrated battery pack incorporates a cylindrical battery. Some battery packs are not cylindrical batteries but also incorporate rectangular batteries. As shown in FIG. 9, a battery pack containing a prismatic battery has a PTC element P having a rectangular shape along the outer shape of the prismatic battery and including the end face of the unit cell 1.
[0029]
The PTC layer 2 is located at the end electrode 1A of the unit cell 1 and has a through hole 2B. The through-hole 2B is provided for connecting the first electrode 3 and the second electrode 4 to the end electrode 1A of the unit cell 1, so that the first electrode 3 and the second electrode 4 are electrically connected to the end electrode 1A. It is opened to the size that can be done. In the illustrated PTC layer 2, the size of the through-hole 2 </ b> B is the same as that of the projection electrode 1 b of the unit cell 1. However, the through-hole does not necessarily have to be the same size as the projection electrode. It can be larger or smaller than the convex electrode. The area of the PTC layer can be increased by reducing the size of the through hole. However, a small through hole makes it difficult to connect the first electrode and the second electrode to the end electrode over a large area. Conversely, if the through hole is enlarged, the area of the PTC layer is reduced, but the first electrode and the second electrode can be connected to the end electrode with a large area.
[0030]
The first electrode 3 and the second electrode 4 are connected to the end electrode 1A of the unit cell 1 by spot welding. Therefore, the through-hole 2B is opened in such a size that the welding electrode can be inserted therein and the first electrode 3 and the second electrode 4 can be connected to the end electrode 1A. Further, the first electrode 3 and the second electrode 4 connected to both surfaces of the PTC layer 2 have through holes 3B, 4B respectively at positions facing the through holes 2B of the PTC layer 2 so that welding electrodes can be inserted. Provided. These through holes 3B, 4B are opened to a size substantially equal to the through hole 2B of the PTC layer 2.
[0031]
The first electrode 3 and the second electrode 4 in FIG. 7 are thin metal plates, and are cut into the same outer shape as the PTC layer 2. The first electrode 3 protrudes a portion of the PTC layer 2 located in the through hole 2B from the lower surface to form a projection 3A, and the projection 3A is connected to the end electrode 1A of the unit cell 1. The convex portion 3A is formed to have a slightly smaller outer shape than the through hole 2B.
[0032]
The second electrode 4 has a projection 4A that is inserted into the through hole 2B of the PTC layer 2. The projecting portion 4A projects higher than the projecting portion of the first electrode 3 so as to penetrate the PTC layer 2 and project from the lower surface. As shown in FIG. 5, the first electrode 3 and the second electrode 4 have the bottom surfaces of the projections 3A and 4A exactly on the same plane. The first electrode 3 and the second electrode 4 having this structure can be connected to the flat electrode 1a which is the end electrode 1A of the two unit cells 1 and the convex electrode 1b, which are exactly on the same plane.
[0033]
However, in the battery pack of the present invention, the projections of the first electrode and the second electrode do not necessarily need to be arranged exactly on the same plane. For example, the first electrode may have a planar shape, or may have a shape that protrudes upward in FIG. 8 and is inserted into the through hole of the PTC layer. The protrusion inserted into the through-hole of the PTC layer is sized so that the protrusion electrode of the unit cell can be inserted, and is connected with the protrusion electrode inserted therein.
[0034]
As shown in the above figures, the first electrode 3 and the second electrode 4 having the same outer shape as the PTC layer 2 have a feature that the contact area with the PTC layer 2 can be increased. The first electrode 3 and the second electrode 4 do not necessarily have to be equal to the outer shape of the PTC layer 2. For example, although not shown, the outer shapes of the first electrode and the second electrode can be slightly smaller or larger than the PTC layer.
[0035]
The battery pack having the above structure is assembled as follows.
(1) In the PTC element P, the first electrode 3 is connected to the lower surface of the PTC layer 2 and the second electrode 4 is connected to the upper surface in advance.
(2) The PTC element P connecting the first electrode 3 and the second electrode 4 is placed on the unit cells 1 arranged in parallel. The PTC element P is mounted on the outer periphery of the two unit cells 1 so as to match the outer periphery thereof.
{Circle around (3)} A welding electrode is inserted into the through hole 2B of the PTC layer 2, and the projections 3A and 4A of the first electrode 3 and the second electrode 4 are spot-welded to the end electrode 1A of the unit cell 1 and connected. .
{Circle around (4)} The unit cell 1 to which the PTC layer 2 is connected is covered with the casing 5 to form a battery pack.
[0036]
【The invention's effect】
The battery pack of the present invention and the PTC element incorporated in the battery pack have a structure in which the first electrode and the second electrode of the PTC element are easily connected to the end electrodes of the unit cell. There is a feature that the area of the PTC layer connecting the electrodes on both sides can be increased without greatly protruding outside. This is because the battery pack and the PTC element of the present invention have a unique structure of the PTC layer, the first electrode, and the second electrode. The PTC layer is formed into a shape including substantially the entire end surfaces of the two unit cells connecting the first electrode and the second electrode, and is located at the end electrode of the unit cell and has a through hole. . The first electrode and the second electrode are connected to an end electrode of the unit cell at a portion of the through hole provided in the PTC layer. With this structure, the pack battery in which the first electrode and the second electrode are connected to the end electrodes, and the PTC layer is disposed on the end faces of the plurality of batteries, the PTC layer has an extremely large area, and the internal resistance is extremely low. it can. Therefore, when the unit cell is used in a normal state, the current loss of the PTC layer can be made extremely small, and the power of the unit cell can be effectively supplied to the load. Further, since the area of the PTC layer can be increased, a large current can flow through the PTC layer. For this reason, the battery pack of the present invention and the PTC element built in the battery pack also have a feature that they can be safely used with a large current load.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a conventional battery pack. FIG. 2 is an exploded perspective view of another conventional battery pack. FIG. 3 is a perspective view of a PTC element incorporated in another conventional battery pack. FIG. 5 is a plan view of the battery pack according to the embodiment of the present invention. FIG. 6 is a plan view of the battery pack shown in FIG. 5. FIG. 7 is a plan view of the battery pack shown in FIG. FIG. 8 is an exploded perspective view of a PTC element incorporated in the battery pack shown in FIG. 8; FIG. 9 is a sectional view of a PTC element incorporated in the battery pack shown in FIG. 5; Description】
DESCRIPTION OF SYMBOLS 1 ... Unit cell 1A ... End electrode 1a ... Plane electrode 1b ... Convex electrode 2 ... PTC layer 2A ... Center hole 2B ... Through-hole 3 ... First electrode 3A ... Convex part 3B ... Through-hole 4 ... Second electrode 4A ... Convex part 4B ... Through hole 5 ... Casing 5A ... Electrode window P ... PTC element

Claims (7)

横に並べて平行に配設されている複数本の素電池（１）と、端部電極（１Ａ）を同一ないしほぼ平面に配設しているふたつの素電池（１）の端部電極（１Ａ）に、ＰＴＣ層（２）の両面に接続されてなる第一電極（３）と第二電極（４）を接続して、素電池（１）と直列に接続されて、素電池（１）を過大電流から保護するＰＴＣ素子（Ｐ）とを備えるパック電池において、
ＰＴＣ層（２）の外形が、第一電極（３）と第二電極（４）を接続するふたつの素電池（１）の端面のほぼ全体を含む形状に成形されると共に、素電池（１）の端部電極（１Ａ）に位置して貫通孔（２Ｂ）が開口されており、
ＰＴＣ層（２）の両面に接続される第一電極（３）と第二電極（４）は、ＰＴＣ層（２）の外形にほぼ等しい外形に形成され、
第一電極（３）と第二電極（４）は、ＰＴＣ層（２）の貫通孔（２Ｂ）に位置する部分を素電池（１）の端部電極（１Ａ）に接続してなることを特徴とするパック電池。A plurality of unit cells (1) arranged side by side and in parallel, and end electrodes (1A) of two unit cells (1) in which the end electrodes (1A) are arranged on the same or substantially flat surface. ), The first electrode (3) connected to both surfaces of the PTC layer (2) and the second electrode (4) are connected, and connected in series with the unit cell (1) to form the unit cell (1). And a PTC element (P) for protecting the battery from excessive current,
The outer shape of the PTC layer (2) is formed into a shape including substantially the entire end faces of the two unit cells (1) connecting the first electrode (3) and the second electrode (4), and the unit cell (1) is formed. ), A through hole (2B) is opened at the end electrode (1A),
The first electrode (3) and the second electrode (4) connected to both surfaces of the PTC layer (2) are formed to have an outer shape substantially equal to the outer shape of the PTC layer (2),
The first electrode (3) and the second electrode (4) are formed by connecting a portion of the PTC layer (2) located in the through hole (2B) to an end electrode (1A) of the unit cell (1). Characteristic battery pack. ＰＴＣ層（２）の上面に接続してなる第二電極（４）が、ＰＴＣ層（２）の貫通孔（２Ｂ）に挿入される凸部（４Ａ）を有し、凸部（４Ａ）を素電池（１）の端部電極（１Ａ）に接続してなる請求項１に記載されるパック電池。The second electrode (4) connected to the upper surface of the PTC layer (2) has a convex portion (4A) inserted into the through hole (2B) of the PTC layer (2). The battery pack according to claim 1, wherein the battery pack is connected to an end electrode (1A) of the unit cell (1). ＰＴＣ層（２）の下面に接続してなる第一電極（３）が、ＰＴＣ層（２）の貫通孔（２Ｂ）に位置する部分を下面から突出させて、凸部（３Ａ）を素電池（１）の端部電極（１Ａ）に接続してなる請求項１に記載されるパック電池。The first electrode (3) connected to the lower surface of the PTC layer (2) protrudes a portion of the PTC layer (2) located in the through hole (2B) from the lower surface, so that the protrusion (3A) is formed on the unit cell. The battery pack according to claim 1, which is connected to the end electrode (1A) of (1). 素電池（１）が円筒電池で、ＰＴＣ層（２）と第一電極（３）と第二電極（４）の外形が、長方形のコーナー部を円筒電池に沿って面取りした形状である請求項１に記載されるパック電池。The unit cell (1) is a cylindrical battery, and the outer shape of the PTC layer (2), the first electrode (3), and the second electrode (4) has a shape in which a rectangular corner is chamfered along the cylindrical battery. 2. The battery pack according to item 1. ＰＴＣ層（２）の両面に接続している第一電極（３）と第二電極（４）を、横に並べて平行に配設される複数本の素電池（１）の端部電極（１Ａ）に接続して、素電池（１）を過大電流から保護するＰＴＣ素子において、
ＰＴＣ層（２）の外形が、第一電極（３）と第二電極（４）を接続するふたつの素電池（１）の端面のほぼ全体を含む形状に成形されると共に、素電池（１）の端部電極（１Ａ）に位置して貫通孔（２Ｂ）が開口されており、
ＰＴＣ層（２）の両面に接続される第一電極（３）と第二電極（４）は、ＰＴＣ層（２）の外形にほぼ等しい外形に形成され、
第一電極（３）と第二電極（４）が、ＰＴＣ層（２）の貫通孔（２Ｂ）に位置する部分を素電池（１）の端部電極（１Ａ）に接続するように構成されてなることを特徴とするパック電池に内蔵されるＰＴＣ素子。The first electrode (3) and the second electrode (4) connected to both surfaces of the PTC layer (2) are arranged side by side and end electrodes (1A) of a plurality of unit cells (1) arranged in parallel. ) To protect the unit cell (1) from excessive current,
The outer shape of the PTC layer (2) is formed into a shape including substantially the entire end faces of the two unit cells (1) connecting the first electrode (3) and the second electrode (4), and the unit cell (1) is formed. ), A through hole (2B) is opened at the end electrode (1A),
The first electrode (3) and the second electrode (4) connected to both surfaces of the PTC layer (2) are formed to have an outer shape substantially equal to the outer shape of the PTC layer (2),
The first electrode (3) and the second electrode (4) are configured to connect a portion of the PTC layer (2) located in the through hole (2B) to the end electrode (1A) of the unit cell (1). A PTC element built in a battery pack. ＰＴＣ層（２）の上面に接続してなる第二電極（４）が、ＰＴＣ層（２）の貫通孔（２Ｂ）に挿入される凸部（４Ａ）を有し、凸部（４Ａ）を素電池（１）の端部電極（１Ａ）に接続するように構成されてなる請求項５に記載されるパック電池に内蔵されるＰＴＣ素子。The second electrode (4) connected to the upper surface of the PTC layer (2) has a convex portion (4A) inserted into the through hole (2B) of the PTC layer (2). The PTC element built in a battery pack according to claim 5, wherein the PTC element is configured to be connected to an end electrode (1A) of the unit cell (1). ＰＴＣ層（２）の下面に接続してなる第一電極（３）が、ＰＴＣ層（２）の貫通孔（２Ｂ）に位置する部分を下面から突出させて、凸部（３Ａ）を素電池（１）の端部電極（１Ａ）に接続するように構成されてなる請求項５に記載されるパック電池に内蔵されるＰＴＣ素子。The first electrode (3) connected to the lower surface of the PTC layer (2) protrudes a portion of the PTC layer (2) located in the through hole (2B) from the lower surface, so that the protrusion (3A) is formed on the unit cell. The PTC element built in a battery pack according to claim 5, wherein the PTC element is configured to be connected to the end electrode (1A) of (1).
JP25378197A 1997-09-18 1997-09-18 Battery pack and PTC element built in this battery pack Expired - Fee Related JP3576767B2 (en)

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CNB988108127A CN1161847C (en) 1997-09-18 1998-09-17 Battery pack and PTC element incorporated in the battery pack
AT98943017T ATE212477T1 (en) 1997-09-18 1998-09-17 BATTERY PACK AND PTC ELEMENT INTEGRATED THEREIN
EP98943017A EP1026758B1 (en) 1997-09-18 1998-09-17 Battery pack and ptc element incorporated in the battery pack
DE69803596T DE69803596T2 (en) 1997-09-18 1998-09-17 BATTERY PACK AND PTC ELEMENT INTEGRATED IN IT
AU90948/98A AU9094898A (en) 1997-09-18 1998-09-17 Battery pack and ptc element incorporated in the battery pack
US09/508,940 US6356051B1 (en) 1997-09-18 1998-09-17 Battery pack and PTC element incorporated in the battery pack
PCT/JP1998/004177 WO1999014814A1 (en) 1997-09-18 1998-09-17 Battery pack and ptc element incorporated in the battery pack

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